Light emitting device including nearly index-matched luminescent glass-phosphor composites

ABSTRACT

A light emitting device includes a light emitting diode (LED); a transparent optic having a refractive index n optic ; and a phosphor layer spaced apart from the LED and positioned between the LED and the transparent optic. The phosphor layer has an effective refractive index n phosphor , where a gap between the LED and the phosphor layer has a refractive index n gap  that is less than n phosphor . The transparent optic has an inner convex surface in contact with the phosphor layer. The inner convex surface has an inner radius of curvature r; and an outer convex surface facing away from the phosphor layer and being a surface through which the light emitting device emits light into a medium adjacent the outer convex surface. The medium has a refractive index n medium . The outer convex surface has an outer radius of curvature R, such that r/R is equal to n medium /n optic .

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 14/444,829, filed Jul. 28, 2014, which is acontinuation of U.S. patent application Ser. No. 13/794,060, filed Mar.11, 2013, which is a continuation application of U.S. patent applicationSer. No. 12/669,579, filed Jun. 28, 2010, which is a 371 ofInternational Application PCT/US2008/070621, filed Jul. 21, 2008, whichin turn, is a non-provisional application of U.S. ProvisionalApplication No. 60/961,185, filed Jul. 19, 2007, the disclosures ofwhich are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to the field of solid-statelighting and more specifically to high efficiency phosphor-convertedLEDs.

BACKGROUND

Solid-state lighting (SSL) is a type of lighting that does not use anelectrical filament or a gas in the production of light. A primaryadvantage of SSL over conventional lighting technologies is thepotential energy savings as a result of its higher luminous efficienciesover conventional lighting devices. For example, SSL is capable of 50%efficiency with 200 lumen per watt (lm/W) efficacy (compared to 15 lm/Wfor incandescents and 60-90 lm/W for fluorescents) and up to 100 khrlifetimes. This is approximately 100 times the lifetime of conventionalincandescent bulbs and 10 times the lifetime of fluorescents. TheDepartment of Energy (DOE) has set a goal of 50% electrical-to-opticalsystem efficiency with a spectrum accurately reproducing the solarspectrum by 2020. The Optoelectronic Industry Development Association(OIDA) aims for 200-hm/W luminous efficiency with a color renderingindex greater than 80.

Each of these conventional methods and devices has deficiencies. Colormixing is hindered by the absence of an efficient LED material in the500 nm to 580 nm (green to-yellow) range. Wavelength conversion suffersfrom phosphor conversion loss and package designs that do not extractphosphor-converted light efficiently.

SSL devices primarily include light emitting diodes (LEDs), whichinclude a small chip semiconductor, i.e. the LED source, mounted in areflector cup on a lead frame. The LED source generates photons of lightat a first wavelength when energized. The reflector cup reflects photonsout of the LED. An optic, generally a silicone or epoxy encapsulation,aids in light extraction from the LED source and protects the LEDcomponents.

High efficiency generation of white light with LEDs has conventionallybeen according to one of three methods: 1) color mixing; 2) wavelengthconversion; or 3) a combination of methods 1 and 2. Color mixing is theuse of multiple LEDs across the visible spectrum (e.g. blue+green+redLEDs), which combine to produce a white light. Wavelength conversion isthe use of a single, efficient, short wavelength LED emitting light atthe first wavelength, which is then at least partially absorbed by aphosphor within the LED and re-emitted at a second wavelength. LEDsunder method 2 are generally referred to as phosphor-converted LEDs(pcLEDs).

Conventional pcLEDs have generally two structural arrangements. First,the phosphor can encompass the LED source of the LED. The phosphor istypically a YAG:Ce crystalline powder in direct contact with the bluewavelength emitting LED source. Both are positioned upon a heat sinkbase and surrounded by an optic. The other arrangement is a scatteredphoton extraction (SPE) pcLED, which positions a planar phosphor-layerat a distance away from the LED source. Herein, the YAG:Ce phosphor, inpowder form, creates a diffuse, semitransparent layer upon an acrylicoptic with a planar surface.

When the phosphor is in direct contact with the LED source, the phosphorsuffers from optical losses by reflection of phosphor-emission back intothe LED source rather than through the optic and out of the LED. Thiscan account for up to 60% of the total phosphor emission. The SPE pcLEDsuffers from scattering of the phosphor emissions. Scattering is theresult of substantial differences in the indices of refraction of thephosphor powder and the material that encapsulates the phosphor (air,silicon, PMMA, or glass). The index of refraction, n, is a measure ofthe relative speed of light in a medium as compared to in a vacuum(where n.sub.vac=1). When light passes from one medium to another mediumwith a substantially different index of refraction, the speed anddirection of the light changes and is known as refraction. Refractioncan lead to a randomization, or scattering, of the directionality of thelight. Scattering then reduces efficiency by increasing the path length(a) inside the phosphor layer by trapping of the emissions by totalinternal reflection and (b) inside the device package because of randomdirectionality of the phosphor emission, both of which can lead toreabsorption and optical loss.

These phosphor-related deficiencies are then compounded by secondarylosses encountered by other package design deficiencies, such asimperfections of the reflector cup within the LED. While the reflectorcup is intended to direct the phosphor-emission out of the LED, internalreflections and path randomization can trap a portion of thephosphor-emission, such as between the reflector cup and the phosphor,and decrease LED efficiency by approximately 30%.

Thus, to reach the efficiency goals set forth by the DOE, the problemsassociated with package design must be eliminated by designing a highefficiency LED that resolves the issues identified above.

SUMMARY OF THE INVENTION

According to the embodiments of the present invention, a light emittingcomposite material is described. The light emitting composite materialincludes a glassy material and a plurality of phosphor particlessuspended within the glassy material, wherein the refractive index ofthe plurality of phosphor particles is approximately equal to therefractive index of the glassy material.

The plurality of phosphor particles can be composed of an inorganiccrystalline material selected from the group consisting ofY_(x)Gd_(y)Al_(v)Ga_(w)O₁₂O:M³⁺, wherein x+y=3 and v+w=5; SrGaS₄:M²⁺;SrS:M²⁺; X₂Si₅N₈:M²⁺; and XSi₂O₂N₂:M²⁺, wherein X is selected from thegroup consisting of He, Mg, Ca, Sr, and Ba and wherein M is selectedfrom a group consisting of Ce, Eu, Mn, Nd, Pr, Sm, Gd, Tb, Dy, Ho, Br,Tm, Yb, Lu, Sc, Ti, V, Cr, Pe, Co, Ni, Cu, Zn, Ir, and Pt.

The glassy material can be an optical glass comprising an amount from 5%to about 35% of SiO₂; an amount from about 55% to about 88% of PbO;optionally an amount less than 10% B₂O₃; optionally a combined amountless than 8% of Na₂O and K₂O; and optionally a combined amount less thanabout 15% total of TiO₂, ZrO₂, La₂O₃, ZnO, and BaO.

In other light emitting composites, the glassy material can be anoptical glass comprising an amount from about 21% to about 30% of TIO₂;an amount from about 30% to about 50% of BaO, NaO, BeO, CaO, SrO, CdO,Ga₂O₃, In₂O₃, or Y₂O₃; an amount from about 18% to about 24% of Al₂O₃;and an amount from about 1% to about 10% of SiO₂, B₂O₃, PbO, GeO₂, SnO₂,ZrO₂, HfO₂, or ThO₂.

In another aspect of the present invention, the light emittingcomposites of the present invention can be used within aphosphor-containing light emitting device (pcLED). The pcLED can beconstructed as an Enhanced Light Extraction by Internal Reflection(ELIXIR) LED device.

In yet another aspect of the present invention, the light emittingcomposite can be used with a solid-state laser.

In yet another aspect of the present invention, the light emittingcomposite can be used as a luminescence collector.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a diagrammatic cross-sectional view of the ELIXIR LED deviceaccording an embodiment of the present invention.

FIG. 2 is a sample spectrum demonstrating the LED source emission band,the phosphor absorption band, and the phosphor emission band.

FIG. 3 is a diagrammatic cross-sectional view of the ELIXIR LED deviceaccording to another embodiment of the present invention.

FIG. 4 is an enlarged diagrammatic cross-sectional view of anearly-indexed matched luminescent glass crystal composite.

FIG. 5A is a diagrammatic cross-sectional view of the total internalreflections within a conventional pcLED device.

FIG. 5B is a diagrammatic cross-sectional view that illustrates therelation between the relative radii of first and second materials, whichleads to total internal reflection.

FIG. 6 is a diagrammatic view of a conventional pumped solid-state laserdevice.

FIG. 7 is a diagrammatic view of a pumped solid-state laser deviceaccording to an embodiment of the present invention.

FIG. 8 is a diagrammatic view of a luminescence collector according toan embodiment of the present invention.

FIG. 9 is a diagrammatic cross-sectional view of the result of a raytrace diagram for the ELIXIR LED device according to one embodiment ofthe present invention.

DETAILED DESCRIPTION

Efficiency of a fully wavelength converted pcLED can be expressed asη_(pcL)=η_(LED)·η_(s)·η_(q)·η_(p)   Equation 1where η_(pcL) is the total pcLED efficiency and is dependent upon theefficiency of the particular LED source, η_(LED); the Stokes conversionefficiency, η_(s), which is the quantum ratio of the average emissionwavelengths of the LED and the phosphor; the phosphor quantumefficiency, η_(q), which indicates the efficiency of the quantumconversion of light from a first wavelength to a second wavelengthinside the phosphor; and the package efficiency, η_(p), which is theefficiency of light extraction of LED- and phosphor-emitted photons fromthe LED device package. The product of η_(q)·η_(p) is the conversionefficiency (CE) for an LED device. The embodiments of the presentinvention optimize CE.

Package efficiency, η_(p), of the present invention is improved overconventional LED devices by first separating an LED source 12 from firstand second non-planar layers, wherein the second layer is composed of aphosphor 14, which will nearly eliminate the reflection of phosphor- andLED-emissions back into the LED source 12. Secondly, a planar reflector16 is used to reduce the number of mirror reflections over theconventional LED. The result is an Enhanced Light eXtraction by InternalReflection (ELIXIR) LED device 10, shown in FIG. 1.

The ELIXIR LED 10 more specifically includes the first non-planar layer,i.e. a glass cover 18, surrounding and making immediate contact with thesecond non-planar layer, i.e. a phosphor 14, and a LED source 12 upon aheat sink base 20. The phosphor 14 and the LED source 12 are separatedby a radius sufficient to substantially reduce the likelihood ofphosphor-emissions reentering the LED source 12. This distance, r, isdependent upon a specified fraction of reentry, P, and is given by:r≦√[A/(4·π·P)]  Equation 2

Herein, A is the size of the LED source 12, i.e. the surface area of theLED chip. The high package efficiency is maintained as long as theproportions of the ELIXIR LED 10, namely the r_(phosphor)/r_(optic)ratio, are preserved, as described below in connection with FIG. 5B. TheELIXIR LED 10 size is ultimately limited by the size of the LED source12. The distance to the phosphor 14 from the LED source 12 must besufficiently long so that only a small fraction of converted lightre-enters the LED source 12, where high losses occur. For example, atypical power LED chip has an area of ˜1 mm². If we specify that lessthan 1% of phosphor light emitted from any point on the phosphor 14 mayreenter the LED source 12, a minimum LED source 12 to phosphor 14separation of approximately √1 mm²/(4π(0.01)), or ˜2.8 mm is obtained.The minimum ELIXIR LED 10 diameter would be four times this value, ˜1.1cm, which is approaching the size of the transparent lens encapsulationand smaller than the heat sink diameter on a typical power LED.

The LED source 12 can include any conventional resonance cavity LED orlaser diode source generally emitting a light having a first wavelengthranging between about 350 nm to about 500 nm. This can include, butshould not be limited to, a blue power LED with a peak wavelength of 455nm with a 1000 mA DC drive capability.

The glass cover 18 can be any material suitable for the lensconstruction and for protection of the phosphor 14 and LED source 12,such as polymethyl methacrylate (PMMA) silicones, and glasses. In analternative embodiment described herein, the glass cover 18 and thephosphor 14 may he made integral.

The phosphor 14 is applied to the glass cover 18 as a layer of inorganicphosphor crystalline powder. The phosphor 14 can be applied as a layer,for example, of about 100 μm in thickness, to an inner surface of theglass cover 18 from a solution of acetone or other solvent. The phosphor14 should be selected such that the phosphor absorption bandsubstantially overlaps with the LED-emission band, as shown in FIG. 2.This ensures efficient transfer from the first wavelength, theLED-emission, to the second wavelength, the phosphor-emission. Thus, asuitable phosphor for use with the blue power LED source can be JohnsonPolymer Joncryl 587 modified styrene acrylic with 0.2% BASF Lumogen FYellow 083 fluorescent dye.

Though not specifically shown, the glass cover 18 can be eliminated andthe phosphor 14 is applied as a layer upon the inside radius of ahemispherical optic 22.

While the phosphor 14, glass cover 18, and optic 22 are generallyillustrated and explained with a hemispherical shape, the shape shouldnot be considered so limited. That is, the shape can include hemispheres(see FIG. 1), ellipsoids, spheres 24 (see FIG. 3), or other similarshapes as is desired or necessary. In this way, the phosphor 26, glasscover 28, and optic 30 will include an opening 34 for electricalconnections 36 and support 38 to the LED source 32. While not necessary,the opening 34 should be small in construction to further minimizeemission losses.

In optimizing η_(q) of Equation 1 and the ELIXIR LED 10 of FIG. 1, thephosphor 14 and glass cover 18 are replaced with a light emittingcomposite material 40 of FIG. 4. The light emitting composite material40 integrates the first and second non-planar layers as an inorganiccrystalline 42 suspended in a glassy material 44 matrix as illustratedin FIG. 4. The inorganic crystalline 42 and glassy material 44 areselected such that, n_(c), the index of refraction of the inorganiccrystalline 42 is approximately equal, n_(g), to the index of refractionof the glassy material 44. The result is a nearly index-matchedluminescent glass-crystal composite (NIMLGCC) 40 that maximizes thequantum efficiency of the phosphor by reducing, or eliminating, opticalscattering.

Because of their large surface-to-volume ratio, nanoparticles have lowquantum efficiencies. Thus, the inorganic crystalline 42 should be aparticle 46 that is larger than about 10 nm, i.e. not a nanoparticle.However, because the light-emitting composite material 40 has a finitethickness, the inorganic crystalline 42 should be smaller than thethickness of the light-emitting composite material 40. Suitableinorganic crystalline 42 can include Y_(x)Gd_(y)Al_(v)Ga_(w)O₁₂:M³⁺,wherein x+y=3 and v+w=5; SrGa₂S₄:M²⁺; SrS:M⁺; X₂Si₅N₈:M²⁺; andXSi₂O₂N:M²⁺, wherein X is selected from a group consisting of Be, Mg,Ca, Sr, and Ba and wherein M is selected from a group consisting of Ce,Eu, Mn, Nd, Pr, Sm, Gd, Ib, Dy, Ho, Er, Tm, Yb, Lu, Sc, Ti, V, Cr, Fe,Co, Ni, Cu, Zn, Ir, and Pt.

It would be permissible for the light-emitting composite material 40 tocomprise a combination of different inorganic crystallines 42 to obtaina color mixing result of broadband white light emission. For example,two or more UV- or violet-short wavelength inorganic crystallinematerials 42 in the 350 nm to 430 nm range will absorb the firstwavelength from the LED source 12 and reemit a combination of red,green, and blue light to achieve a broadband white. The broadband whiteresulting from a color-mixing light-emitting composite 40 is more highlyuniform as compared to conventional phosphor color mixing because theemissions of red, green, and blue originate from the same location. Inanother example, where blue or blue-green short wavelength LED sources12 are used (430 nm to 500 nm), these inorganic crystalline materials 42will reemit the first wavelength in combination with red and green lightto achieve a broadband white.

The glassy material 44 in which the inorganic crystalline material issuspended can include an optical glass or other glass material, such asthose manufactured by Schott North America (Elmsford, N.Y.) includingSF-57, SF-67, LASF-9. LASRP47, SK-57. PK-51, PK-53, FK-51A, and FK-5.Other optical glasses can include those according to the teachings ofU.S. Appl. No. 2005/0075234 or U.S. Pat. No. 3,960,579, which are herebyincorporated by reference, in their entirety.

The glassy material 44 can comprise about 10% to about 99.9% of thelight emitting composite material 40 by weight.

As indicated above, the selection of an inorganic crystalline 42 andglassy material 44 should be according to index-matching. That is, theindex of refraction, n_(c), of the inorganic crystalline 42 should beapproximately equal to the index of refraction, n_(g), of the glassymaterial to provide an index of refraction, nz, for the light-emittingcomposite material 40.

By nearly index-matching the inorganic crystalline 42 to the glassymaterial 44, scattering induced loss is nearly eliminated. That is, byestablishing no n_(g) that is approximately equal to n_(c), thephosphor-emission will travel at a speed within the inorganiccrystalline 42 that is approximately equal to the travel speed withinthe glassy material 44 and thus reduce refraction, or a change in thedirection of the emission. As a result scattering is reduced and η_(p)increased.

Total internal reflections occur when the interface between first andsecond material 52, 54 cannot be traversed by light, as illustrated witha conventional LED device 50 in FIG. 5A. This condition at the interfaceoccurs when the refractive index of the first material 52 (here thephosphor) is greater than the refractive index of the second material54. According to Snell's Law, the light cannot traverse the interface,but will either refract along the interface or undergo total internalreflection. Total internal reflection of the emission 58 continues untilall of the energy in the emission is reabsorbed 60 by the phosphor.

FIG. 5B shows a hemispherical optic 22 having an internal radius, r, andan outer radius, R. Here, phosphor 14 (which includes, e.g. thelight-emitting composite material 40) is located at the internal radiusr of the optic 22. Ideally, the optic 22 is constructed from the sametransparent material as a host material of the phosphor 14 (e.g. thehost material 44 of the light-emitting composite material 40.) In thismanner, a refractive index n₂ of the optic 22 is equal to or larger thanthe refractive index of the phosphor 14. A refractive index of themedium that surrounds the optic 22 is n₁. Snell's Law can be used tocalculate a configuration of the optic 22 for which total internalreflections are eliminated inside the optic 22. This configuration isdeterminable by establishing a ratio of a radius to the phosphor 14(which includes, e.g. the light-emitting composite material 40), r, to aradius to the outer diameter of the optic 22, R. This ratio of radiimust be less than or equal to the ratio of the index of refraction formaterial external to the optic 22 (and, hence, external to the ELIXIRLED device 10), n₁, and n₂:r/R≦n ₁ /n ₂   Equation 3

Often, this material external to the ELIXIR LED 10 will be air, orvacuum, having n₁=1. Thus, total internal reflection inside the optic 22will be avoided when r/R is less than the inverse of n₂.

The ELIXIR LED 10 of FIG. 9 includes a planar reflector 16, an LEDsource 12 protruding through the planar reflector 16, a phosphor 14—inthis case including the light-emitting composite material 40—and anoptic 22. The phosphor 14 is spaced apart from the LED source 12, suchthat an enclosure formed by the phosphor 14 and the planar reflector 16encloses the LED source 12. In this case, a medium inside the enclosureis air, with refractive index n=1. The phosphor 14 and the optic 22 arecoupled together and positioned upon the planar reflector 16 as providedby Equation 3. Materials for the planar reflector 16 can includealuminized Mylar attached to an acrylic sheet or a 3M Vikuiti enhancedspecular reflector film. By eliminating the reflector cup ofconventional, LED package design, phosphor-emission can leave the ELIXIRLED 10 without being trapped between the planar reflector 16 and thephosphor 14.

Finally, the optic 22 positioned externally to the light-emittingcomposite material 40 can be constructed of a glass material similar tothe glassy material 44 of the light-emitting composite material 40.Other materials can also be used so long as refractive index of theoptic 22 is greater than or equal to n₂. Suitable materials for theoptic 22 construction can be polymethyl methacrylate (PMMA), silicones,and glasses having refractive indices of about 1.3 to about 2.2.

When PMMA is used in constructing the optic 22, the method can includepolymerization of a methyl methacrylate monomer around a 25 mL roundbottom flask to form an inner radius of the optic 22 with an innerdiameter of approximately 3.8 cm. The outer diameter of the optic 22 canbe shaped, for example, by an aluminum mold. However, other fabricationmethods would be known and the size could be varied according to aparticular need.

The monomer for constructing the optic 22 can be purified to eliminatecontaminants. For PMMA, the methyl methacrylate monomer can be washedwith a solution of sodium hydroxide, rinsed with deionized water, anddried with anhydrous magnesium sulfate. Polymerization can be initiatedby benzoyl peroxide and heating the solution to 90° C. The resultantviscous solution is then poured into a mold, such as the one describedpreviously, and then cured in an oven at 35° C. for one week.

The optic 22 could also be produced with a high quality injectionmolding of PMMA rather than polymerization.

While the ELIXIR LED 10 of FIG. 9 is generally shown to include an airgap 62, it would be understood that the air gap 52 can be partially, orcompletely, replaced with a glass or polymer having an refractive indexless than or equal to n₂.

In other embodiments, the NIMLGCC can be used with visible diode-pumpedsolid-state lasers 84 as illustrated in FIG. 7. Conventionaldiode-pumped solid-state lasers 64 (see FIG. 6) include a light source66 comprising a power source 68 providing energy to a diode pump 70,such as AlGaAs laser diode. Photons emitted from the diode pomp 70 aredirected into a laser cavity 74 by a fiber 72. The photons entering thelaser cavity 74 are directed to a population inversion crystal 76, suchas a YAG:Nd, which when excited by the photons will emit a light at afirst wavelength (at 1064 nm). Light of this first wavelength can thenreflect between input and output mirrors 75, 80 and yield a coherentemission, characteristic of the solid-state loser 64. A portion of thefirst wavelength will impact a doubling crystal 82, such as a potassiumtitanium oxide phosphate (KTP) crystal, which doubles the frequency ofthe light (conversion of the first wavelength to a second wavelengthequal to 532 nm). Light of the second wavelength is not reflected by theoutput mirror 80, but rather passes through the output mirror 80 as thelaser output.

However, the YAG:Nd population inversion crystal 76 and KTP doublingcrystal 82 are a highly expensive component of the conventional pumpedsolid-state laser 64. The NIMLGCC, as explained above, can provide aneconomical and energetically efficient alternative to the conventionalpumped solid-state laser 64.

For example, as in FIG. 7, the YAG:Nd population inversion crystal 76and NTP doubling crystal 82 are replaced by an NIMLGCC crystal 86 in thepumped solid-state laser 84 according to the present invention. TheNIMLGCC crystal 86 can be constructed in a manner as described above andis generally molded and polished to a typical optics standard. In thisway, a first wavelength, such as from a 405 nm emitting Indium GalliumNitride (InGaN) diode 88 of the light source 67, reflects between theinput and output mirrors 78, 80 as a coherent emission within lasercavity 75. At least a portion of this first wavelength can be absorbedby the NIMLGCC crystal 86 and a second wavelength is emitted. Thissecond wavelength will traverse the output mirror 80 and will be emittedas the laser output.

In yet another embodiment, the NIMLGCC can be used as a luminescencecollector 90 for energy conversion, as shown in FIG. 8. Therein, theNIMLGCC is molded into a sheet acting as a light tube 92. As a lighttube 92, the phosphor emissions 94 will be contained as total internalreflections 96, which are directed toward first and second ends 98, 100of the light tube 92. Total internal reflection 96 is accomplished bythe selection of an NIMLGCC material for the light tube 92 in accordancewith Snell's law and as described previously. Thus, the NIMLGCC materialshould be selected so as to maximize the total internal reflections 96from the phosphor emissions 94 while minimizing transmitted light 102.

In operation of the light tube 92, a light source 104 emits a firstwavelength incident 106 to the light tube 92. The first wavelength isabsorbed by an inorganic crystalline 42 within the NIMLGCC light tube 92and reemitted at a second wavelength. This second wavelength istransmitted through the light tube 92 by total internal reflection 96 tothe first or second ends 98, 100 of the light tube 92. As the secondwavelength leaves the light tube 92 at the first or second ends 98, 100as reflected light 108, the reflected light 108 impacts a photovoltaiccell 110. The photovoltaic cell 110 collects a substantial portion ofthe reflected light 108 and converts the reflected light 108 intoanother energy, such as electrical current.

The light tube 92 can be constructed with a small edge profile, whichenables the use of a relatively small photovoltaic cell 110. Thus, thefirst and second ends 98, 100 of the light tube 92 are approximatelysimilar in size to the surface area of the photovoltaic cell 110. Thisallows for increased likelihood that the reflected light 108 will impactthe photovoltaic cell 110.

Suitable materials for the photovoltaic cell are known, but cangenerally include Si, Ge, GaAs, AlAs, InAs, AlP, InP, GaP, ZnSe, orCdSe, or combinations thereof.

EXAMPLE 1

The efficiency of the ELIXIR LED 10 according to the present inventionis demonstrated with a computer simulation of a ray tracing diagram,shown in FIG. 9. Herein, the ELIXIR LED 10 is constructed as describedabove with a phosphor radius, r, and equal to 1.9 cm.

The ray tracing diagram illustrates the various paths thephosphor-emitting photons can take in exiting the ELIXIR LED 10. Ray 1exits the ELIXIR LED 10 without encountering any reflections andcomprises approximately 35% of the phosphor-emissions. Ray 2(representing approximately 35% of the phosphor-emission) demonstratesone particular benefit of the ELIXIR LED 10. Ray 2 is emitted in adirection toward the planar reflector 16, where substantial emissionsloss occurs in a conventional pcLED package design. However, in theELIXIR LED 10, the phosphor emission is reflected at the phosphor-airinterface 112. Ray 2 can then exit the ELIXIR LED 10 and may avoid theplanar reflector 16 entirely. Ray 3, comprising approximately 17% of thephosphor-emission, heads directly to the reflector 16 before exiting theELIXIR LED 10 and never encounters the phosphor-air interface 112. Ray 4is transmitted across the phosphor-air interface 112 but avoids the LEDsource 12 and recrosses the phosphor-air interface 112 before exitingthe ELIXIR LED 10. The transmissions represented by Ray 4 account forapproximately 13% of the total phosphor emissions. Finally, Ray 5 istransmitted across the phosphor-air interface 112 and enters the LEDsource 12 where the highest losses would occur within conventional LEDpackage designs. In the ELIXIR LED 10 constructed with a radius of thephosphor 14, Ray 5 comprises less than 0.1% of the totalphosphor-emission.

While the invention has been illustrated by a description of variousembodiments and while these embodiments have been described inconsiderable detail, it is not the intention of the applicants torestrict or in any way limit the scope of the appended claims to suchdetail. Additional advantages and modifications will readily appear tothose skilled in the art. Thus, the invention in its broader aspects istherefore not limited to the specific details, representative apparatusand method, and illustrative example shown and described. Accordingly,departures may be made from such details without departing from thespirit or scope of applicants' general inventive concept.

What is claimed is:
 1. A light emitting device comprising: a lightsource; a first non-planar layer spaced apart from the light source by agap, wherein the first non-planar layer is composed of a light emittingcomposite material comprising a glassy material; and a plurality ofphosphor particles suspended within the glassy material, wherein arefractive index of the phosphor particles is approximately equal to arefractive index n₂ of the glassy material; and a second non-planarlayer composed from the glassy material and having an inner non-planarsurface in contact with the first non-planar layer, the inner non-planarsurface having an inner radius of curvature r; and an outer non-planarsurface facing away from the first non-planar layer and being a surfacethrough which the light emitting device emits light into a mediumadjacent the outer non-planar surface, the medium having a refractiveindex n₁, the outer non-planar surface having an outer radius ofcurvature R, that satisfies the condition r/R=n₁/n₂.
 2. The lightemitting device of claim 1, wherein the plurality of phosphor particlesare composed of an inorganic crystalline material selected from thegroup consisting of: Y_(x)Gd_(y)Al_(v)Ga_(w)O₁₂:M³⁺, wherein x+y=3 andv+w=5; SrGa₂S₄:M²⁺; SrS:M²⁺; X₂Si₅N₈M²⁺; and XSi₂O₂N₂:M²⁺, wherein X isselected from the group consisting of Be, Mg, Ca, Sr, and Ba and whereinM is selected from a group consisting of Ce, Eu, Mn, Nd, Pr, Sm, Gd, Tb,Dy, Ho, Er, Tm, Yb, Lu, Sc, Ti, V, Cr, Fe, Co, Ni, Cu, Zn, Ir, and Pt.3. The light emitting device of claim 1, wherein the glassy material isan optical glass comprising: an amount from about 5% to about 35% ofSiO₂; an amount from about 55% to about 88% of PbO; optionally an amountless than about 10% of B₂O₃; optionally a combined amount less thanabout 8% of Na₂O and K₂O; and optionally a combined amount less thanabout 15% total of TiO₂, ZrO₂, La₂O₃, ZnO, and BaO.
 4. The lightemitting device of claim 1, wherein the glassy material is an opticalglass comprising: an amount from about 21% to about 30% of TiO₂; anamount from about 30% to about 50% of BaO, NaO, BeO, CaO, SrO, CdO,Ga₂O₃, In₂O₃, or Y₂O₃; an amount from about 18% to about 24% of Al₂O₃;and an amount from about 1% to about 10% of SiO₂, B₂O₃, PbO, GeO₂, SnO₂,ZrO₂, HfO₂, or ThO₂.
 5. The light emitting device of claim 1, whereinthe glassy material is a Schott glass.
 6. The light emitting device ofclaim 1, wherein the refractive index of the plurality of phosphorparticles is within five percent of the refractive index of the glassymaterial.
 7. The light emitting device of claim 1, wherein the pluralityof phosphor particles are composed of Y₃Al₅O₁₂:Ce³⁺ and the glassymaterial is a Schott glass.
 8. The light emitting device of claim 1,wherein the plurality of phosphor particles have a size ranging fromabout 100 nm to about 100 μm.
 9. The light emitting device of claim 1,wherein the plurality of phosphor particles are composed of an inorganiccrystalline material having a refractive index of about 1.5 to about 2.8and the glassy material has a refractive index of about 1.5 to about2.8.
 10. The light emitting device of claim 1, wherein the light sourceis configured to emit first wavelength ranges from about 350 nm to about500 nm.
 11. The light emitting device of claim 1, wherein the lightsource is selected from the group consisting of a laser, a diode, and aflashlamp.
 12. The light emitting device of claim 1, wherein the lightsource and the first and second non-planar layers are positioned on aplanar reflector.
 13. The light emitting device of claim 1, wherein thefirst and second non-planar layers are integral.
 14. The light emittingdevice of claim 1, wherein the first and second non-planar layers arehemispherical.
 15. The light emitting device of claim 1, wherein thefirst and second non-planar layers are spherical.
 16. The light emittingdevice of claim 1, wherein the gap is an air gap.